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Abstract:

A connector has a housing with a first face of the housing. The housing
supports a plurality of wafers, each wafer supporting a plurality of
terminals and including grooves, the grooves aligned with the terminals
supported by the wafer. The housing may be positioned in a cage that
includes receptacles on a front face of the cage.

Claims:

1. An electrical connector, comprising: an insulative housing; a set of
frames supported by the insulative housing, each frame of the set of
frames including at least four grooves; and at least four terminals
supported by each frame, each of the terminals having tails and contacts
and a body extending therebetween, the tails configured to engage a board
in a first direction and the contacts configured to be engaged in a
second direction that is substantially perpendicular to the first
direction, wherein the four grooves in each of the frames are
correspondingly aligned with the four terminals and wherein at least two
of the grooves respectively expose a substantial portion of corresponding
terminals to air and each the at least two grooves have a first portion
that extends in a direction aligned with second direction and a second
portion that extends at an angle to the second direction.

2. The connector of claim 1, wherein the at least two grooves are further
configured to extend in the first direction.

3. The connector of claim 1, wherein each of the four terminals are
configured to provide differential signaling.

4. The connector of claim 1, each of the four terminals has a bend and
each of the grooves is provided on both sides of the bend.

5. An electrical connector, comprising: an insulative housing; a set of
frames supported by the insulative housing, each frame of the set of
frames including a front edge and a plurality of grooves; and a plurality
of terminals supported by each frame, each of the terminals having tails
and contacts and a body extending therebetween, the contacts extending
from the front edge and the body portion having a substantially uniform
width, the tails configured to engage a board in a first direction and
the contacts configured to be engaged in a second direction that is
substantially perpendicular to the first direction, wherein the plurality
of grooves in each of the frames are correspondingly aligned with the
plurality of terminals and extend from adjacent the front edge a
substantial distance toward the tails, each of the plurality of terminals
including a bend so that they extend in the second direction and then
angle toward the first direction, the plurality of grooves being provided
on both sides of the bend.

6. The electrical connector of claim 5, wherein at least two of the
plurality of grooves further extends in the first direction.

7. The electrical connector of claim 6, wherein at least groove of the
plurality of grooves include a web that bisects the at least one groove.

8. An electrical connector, comprising: an insulative housing; a set of
frames supported by the insulative housing, each frame of the set of
frames including a front edge and a plurality of grooves; and a plurality
of terminals supported by each frame, each of the terminals having tails
and contacts and a body extending therebetween, the contacts extending
from the front edge and the body portion having a substantially uniform
width, the tails configured to engage a board in a first direction and
the contacts configured to be engaged in a second direction that is
substantially perpendicular to the first direction, wherein the plurality
of grooves in each of the frames are correspondingly aligned with the
plurality of terminals so as to cause the plurality of terminals to be
exposed to air and the plurality of grooves extend from adjacent the
front edge in the second direction, each of the plurality of terminals
including a bend so that they extend in the second direction and then
angle toward the first direction after the bend.

9. The electrical connector of claim 8, wherein the grooves are provided
on both sides of the bend.

10. The electrical connector of claim 8, wherein the bend causes the
terminals to angle in the first direction such that a portion of the body
on the first side of the bend is at a right angle to the portion of the
body on the second side of the bend.

Description:

REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of U.S. Ser. No. 13/764,848,
filed Feb. 12, 2013, now U.S. Patent No. TBD, which is a continuation of
U.S. Ser. No. 12/971,128, filed Dec. 17, 2010, now U.S. Pat. No.
8,465,320, which is a continuation of U.S. Ser. No. 12/502,785, filed
Jul. 14, 2009, now U.S. Pat. No. 7,871,294, which is a continuation of
U.S. Ser. No. 12/341,325, filed Dec. 22, 2008, now U.S. Pat. No.
7,575,471, which is a continuation of U.S. Ser. No. 11/881,869, filed
Jul. 30, 2007, now U.S. Pat. No. 7,467,972, all of which are incorporated
by reference in their entirety herein and U.S. Pat. No. 7,467,972 is a
continuation of U.S. Ser. No. 11/130,854, filed May 16, 2005, now U.S.
Pat. No. 7,249,966, which in turn claims priority to prior U.S.
Provisional Patent Applications Nos. 60/571,375, filed May 14, 2004 and
60/584,420, filed Jun. 30, 2004 and 60/584,421, also filed Jun. 30, 2004.

BACKGROUND OF THE INVENTION

[0002] This invention relates to electrical connector assemblies and, more
particularly, to an small sized electrical connectors having a stacked
arrangement.

[0003] Electrical connectors adapted for mounting to printed circuit
boards are known in the art and are commonly used for connection between
two electrical communication devices. In order to ensure that a proper
connection has been made and therefore a link is created between the
electrical communication devices, indicators may be incorporated into
circuits on the printed circuit board. These indicators are typically
light emitting diodes (LEDs) which are turned on when a circuit is
completed between the mating connectors and the communication devices.
Additionally LEDs can be mounted on the printed circuit board to indicate
a number of other conditions including the passage of communications
signals between the two communication devices, indication of power, or
indication that an error in transmitting the signals has occurred.

[0004] A problem arises with these type of connectors because the
terminals of the connector are usually stitched in from the rear of the
connector. Stitched connectors typically require a means to align the
tails of the connector terminals to facilitate the insertion of the
connector onto a circuit board. The use of tail aligners increase the
overall size of the connector, thereby increasing the printed circuit
board "real estate" occupied by the connector.

[0005] Small size connectors must usually be inserted into an exterior
shielding cage by way of a bottom opening. When a dual connector of a
stacked arrangement, i.e., one which is intended to mate with two
electronic modules in a vertically spaced arrangement, is desired, such a
connector cannot be practically inserted into a shielding cage by way of
a bottom opening because of the intervening horizontal wall of the
shielding cage.

[0006] The present invention is therefore directed to a connector having a
construction that overcomes the aforementioned disadvantages and which
easily mates with a shielding cage intended to provide electromagnetic
interference shielding around electronic modules that engage the
connector.

SUMMARY OF THE INVENTION

[0007] Accordingly, it is a principal object of the present invention to
provide a small form factor circuit board connector in a stacked
configuration having engagement faces thereof spaced vertically apart.

[0008] Another object of the present invention is to provide a dual
engagement connector component that is engageable with a light pipe
assembly, the dual engagement connector component having two engagement
areas vertically spaced apart from each other on the component and which
are each surrounded by a metal shield component, the shield component
defining two distinct module-receiving bays which are separated by an
intervening space, the light pipe assembly extending from the connector
component forwardly through the intervening space to provide at least a
pair of indicator lights near the front of the module-receiving bays, the
light pipe assembly engaging the sides or front of the connector
component.

[0009] Yet another object of the present invention is to provide a
connector for use with a shielded assembly having two bays, the connector
having two engagement slots that receive edges of circuit cards that are
associated with electronic modules, the connector having a plurality of
terminal assemblies, each of which holds a plurality of conductive
terminals in a selected arrangement, the terminals being housed in an
insulative skeletal frame.

[0010] A further object of the present invention is to provide a connector
having a small form factor and dual card engagement slots spaced apart
vertically in a housing of the connector, the connector housing having at
least one slot formed on a front face thereof for receiving engagement
members of a shielding assembly.

[0011] Still another object of the present invention is to provide a
terminal assembly for the aforementioned connectors, wherein the terminal
assemblies each include an insulative frame that houses a plurality of
conductive terminals, and the frame includes an engagement member that
extends forwardly from the frame and engages a ledge of the housing to
assist in orienting the terminal assembly in the connector cavity.

[0012] The present invention accomplishes these and other objects by way
of its structure. A connector housing is provided with an internal cavity
formed therein that opens to the rear of the connector housing. This
cavity accommodates a plurality of individual terminal assemblies. Each
terminal assembly includes a dielectric frame that supports a plurality
of conductive terminals. The terminals have aright-angle configuration,
with tail portions of the compliant pin style preferably disposed along
one edge of the frame and with individual contact portions disposed along
another and preferably adjacent edge of the terminal assembly frame.

[0013] These terminal assemblies are inserted into the cavity so that the
contact portions are received within terminal-receiving cavities formed
in the connector housing. The terminal assemblies also preferably include
engagement members which may take the form of clips disposed along the
same edge as the contact portions and these clips engage a shoulder
formed in the connector housing within the connector cavity.

[0014] The internal cavity of the connector housing accommodates the
terminal assemblies and a shoulder member is provided therein as a member
for the terminal assemblies to engage and maintain their orientation
within the housing. The front face of the connector housing may be
provided with slots or cavities disposed between the two card engagement
slots. These other slots receive corresponding opposing engagement
members, preferably in the form of tabs, that extend from a portion of an
exterior shielding assembly and which portion provides an intervening
shielding wall of an associated shielding assembly that divides the
assembly into two distinct module-receiving bays. These slots are
preferably positioned outside of the openings into which the light pipe
engagement members are inserted.

[0015] The front of the connector component may have one or more
engagement slots of cavities formed therein which engage a light pipe
assembly. By this frontal engagement, the sides of the connector housing
need not be modified to engage the light pipes in any fashion, so as to
maintain the reduced size of the connector component. The light pipe
assembly may include hooks that are integrally formed with the light
pipes as a preferable means of attachment. The light pipe assembly may
utilize distinct first and second pairs of light pipes, and each such
pair may utilizes its own set of engagement hooks for engaging the
connector component in the manner described above.

[0016] These and other objects, features and advantages of the present
invention will be clearly understood through a consideration of the
following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The invention will now be described by way of example with
reference to the following figures of which:

[0018] FIG. 1 is an exploded perspective view of a portion of a connector
assembly constructed in accordance with the principles of the present
invention;

[0019] FIG. 2 is a perspective assembled view of the portion of the
connector assembly shown in FIG. 1;

[0020] FIG. 3 is a perspective view of a connector housing incorporated
into the assembly shown in FIG. 1;

[0021] FIG. 4 is perspective view of a first embodiment of a light pipe
assembly that may be used with the connector assembly of FIGS. 1-3;

[0022] FIG. 5 is perspective view of a second embodiment of a light pipe
assembly incorporated into the connector assembly of the present
invention;

[0023] FIG. 6 is a perspective view of the light pipe assembly of FIG. 4
incorporated into the connector assembly, and extending along the sides
thereof;

[0024] FIG. 7 is a partial cutaway perspective view showing the light pipe
assembly of FIG. 5 incorporated into the connector assembly, and
specifically disposed within the exterior shield assembly and partially
within the space dividing the two module-receiving bays of the connector
assembly;

[0025] FIG. 8 is the same view of the connector assembly of FIG. 7, but
with the shield assembly exterior wall shown in place;

[0026] FIG. 9 is an exploded view of a third embodiment of the invention
wherein the light pipes engage the connector component of the assembly by
way of slots disposed in the front face of the connector components, and
which are partially contained within the space separating the two
module-receiving bays of the connector assembly;

[0027] FIG. 10 is the same view as FIG. 9, but with the modules shown in
engagement with their associated connector component and with the
shielding cage assembly removed for clarity;

[0028] FIG. 11 is a perspective view of only the light pipe assembly of
FIG. 9;

[0029] FIG. 12 is the same view as FIG. 11, but with the light pipe end
cap shown exploded away from the light pipes for clarity;

[0030] FIG. 13 is a perspective view of only the two pairs of light pipes
of FIG. 12;

[0031] FIG. 14 is a top plan view of the light pipe and end cap assembly
of FIG. 11, taken along line 14-14 thereof;

[0032] FIG. 15 is a frontal elevational view of the light pipes of FIG.
13, taken along line 15-15 thereof;

[0033] FIG. 16 is an enlarged detail perspective view of FIG. 9,
illustrating only the light pipe and end cap assembly engaged with their
associated connector component and positioned in place on a circuit
board;

[0034] FIG. 17A is a perspective view illustrating the right-side light
pipe in engagement with the connector component of FIG. 16;

[0035] FIG. 17B is the same view as FIG. 17A, but with the light pipe
removed from engagement with the connector component to illustrate better
the manner of engagement between the two components;

[0036] FIG. 18 is a perspective view of a small from factor connector
assembly utilizing another, or fourth, embodiment of a light pipe
assembly constructed in accordance with the principles of the present
invention;

[0037] FIG. 19 is a perspective view, partially exploded, of the connector
assembly of FIG. 18;

[0038] FIG. 20 is the same view as FIG. 19, but with the light pipe and
connector assembly shown separated from the circuit board and the shield
rear end removed to illustrate the manner of insertion of the light
pipe-connector assembly into the shielding cage;

[0039] FIG. 21 is the same view as FIG. 20, but fully exploded to
illustrate all of the components of the overall assembly in which the
present invention is used;

[0041] FIG. 23A is a perspective view of the light pipe-connector
component assembly, and taken from the rear thereof to illustrate the
manner in which the light pipes extend along the sides of the connector
component to face the circuit board illuminators;

[0042] FIG. 23B is the same view as FIG. 23A, but sectioned along line B-B
thereof;

[0043] FIG. 24A is a top plan view of the first, or inner pair of light
pipes;

[0047] FIG. 26A is a top plan view of the first and second pairs of light
pipes nested together;

[0048] FIG. 26B is a front elevational view of FIG. 26A, showing the two
pairs of light pipes in line together;

[0049] FIG. 27 is a perspective view of another alternate embodiment of a
light pipe, endcap and connector assembly;

[0050] FIG. 28 is an exploded view of FIG. 27;

[0051] FIG. 29 is a perspective view of a small form factor connector
constructed in accordance with the principles of the present invention
and which utilizes individual terminal assemblies;

[0052] FIG. 30 is an exploded view of FIG. 30, illustrating the terminal
assemblies removed from their position within the connector housing;

[0053] FIG. 31 is the same view as FIG. 29, but taken from the rear,
illustrating the internal structure of the connector cavity, including
the terminal-receiving slots of the connector housing and the terminal
assembly engagement ledge of the connector housing;

[0054] FIG. 32 is a rear perspective view of FIG. 29, with alternating
ones of the terminal assemblies illustrated in place within the connector
cavity;

[0055] FIG. 33 is a perspective view of a terminal assembly used in the
connector of FIG. 29;

[0056] FIG. 34 is a sectional view of the terminal assembly, illustrating
the lead frame in place within its insulative skeletal frame;

[0057] FIG. 35 is a sectional view of the connector of FIG. 29 mounted on
a circuit board and disposed within an exterior shielding assembly;

[0058] FIG. 36 is a front elevational view of the connector housing of
FIG. 29;

[0059] FIG. 37 is a rear elevational view of the connector housing of FIG.
36, but with the terminal assemblies removed to illustrate the interior
of the connector housing more clearly;

[0060] FIG. 38 is a sectional view of the connector housing of FIG. 37;

[0061] FIG. 39 is a sectional view of the connector assembly of FIG. 36,
illustrating a terminal assembly in place within the connector housing
internal cavity; and,

[0062] FIG. 40 is a perspective view of an array of the connectors of the
invention in place upon a circuit board and mated together with portions
of an exterior shielding assembly.

DETAILED DESCRIPTION OF THE INVENTION

[0063] A connector assembly 10 of the present invention will now be
described generally with reference to FIGS. 1-3. The connector assembly
10 is designed for mounting on a printed circuit board 11. Connector
assembly 10 comprises a connector housing 12 defining a pair of ports 14,
16 each adapted for receiving a portion of a mating connector (not
shown). Herein, the housing port 14 will be referred to as the "lower
port", and housing port 16 will be referred to as the "upper port", but
it will be understood that such terms as "upper", "lower", etc. are used
in this description to facilitate an understanding of the invention and
are not intended to be limiting.

[0064] Upper and lower ports 14, 16 each have a plurality of conductive
terminals 21 mounted therein for engaging complementary terminals of a
mating connector (not shown). To permit space for latching mechanisms for
releasably securing connector assembly 10 in a mated condition with a
complementary mating connector, a cavity 18 may be formed between upper
port 16 and lower port 14 of connector housing 12. Recesses 20 may be
formed in side portions of housing 12, for purposes to be described
below. Recesses 14 may be in communication with housing cavity 18.

[0065] Connector housing 12 may be molded from an insulative,
thermoplastic material. The terminals are mounted in the upper port 16
and the lower port 14 and each terminal has contact portions at an end
thereof (not shown) for engaging complementary contact portions of the
terminals of the mating connector, and tail portions 22 projecting
rearwardly from the contact portions and extending downwardly toward
printed circuit board 11 for electrical connection to respective traces
thereon via through holes formed in (or surface mount pads formed on a
surface of) printed circuit board 11. A tail aligner 24 may be attached
to connector housing 12 using any one of a variety of known methods, such
as a snap-fit, press-fit or mechanical fasteners. The tail aligner 24
includes a plurality of through holes 26 formed therein and which are
configured to match the arrangement of terminal tail portions 22
extending downward toward printed circuit board 11. The tail aligner 24
is mounted onto tail portions 22 of the terminals in the direction of
arrow "A" (FIG. 1) and it sits on the surface of the circuit board 11.

[0066] A pair of shielding cage assemblies 28, 30 are secured to connector
housing 12, with the cage assemblies including a lower cage assembly 28
that is secured to housing 12 to substantially enclose lower port 14
thereof, and an upper cage assembly 30 that is secured to the housing 12
to substantially enclose the upper port 16 thereof. The cage assemblies
28, 30 are typically formed using a material, such as sheet metal or
plated plastic, which conducts and guides magnetic and electric field
energy so as to aid in shielding circuit elements positioned proximate
connector assembly 10 from electromagnetic interference (EMI).

[0067] The lower cage assembly 28 typically includes two interengaging
pieces, a lower base component 32 and a lower cover component 34. The
lower base component 32 has a general U-shaped configuration when viewed
from the front or rear ends, 36, 38 respectively. As such, the lower base
component 32 typically includes three sides, or walls: a base or bottom
wall 40 and two sidewalls 42, 44 that extend upwardly from the bottom
wall 40 and which are spaced apart from each other to define a channel 46
therebetween, into which a portion of the connector housing 12 fits. As
seen in FIGS. 1 and 2, the front and rear portions of lower base
component 32 are left open.

[0068] The lower base component 32 is stamped and formed from metal. The
lower base component 32 may alternatively be formed using other
conductive materials, such as metal-plated plastic or the like. Lower
cover component 34 may also be formed is a similar manner. Generally, the
cover component 34 has a length that matches a corresponding length of
lower base component 32, and a width that is equal to or slightly greater
than a corresponding width of the lower base component 32. The lower
cover component 34 is bent, into a general U-shaped configuration when
looking at it from its front end 50. In this fashion, it includes top
wall 52 and two spaced-apart side walls 54, 56. Lower base component 32
and lower cover component 34 interengage along respective sidewalls
thereof the form an enclosure for at least partially enclosing lower
housing Port 14 of connector housing therein. As seen in FIGS. 1 and 2,
the front and rear portions of the lower cage assembly 28 are left open.
Details of this type of shielding cage are provided in U.S. Pat. No.
6,443,768, which issued on Sep. 3, 2002 and is incorporated herein by
reference.

[0069] The structure of upper cage assembly 30 is similar to that of lower
cage assembly 28 and it includes two interengaging pieces: an upper base
component 58 and an upper cover component 60. The upper base component 58
has a bottom wall 62 and two spaced-apart sidewalls 64, 66. The upper
cover component 60 has a top wall 72 and two spaced apart sidewalls 74,
76. These sidewalls 74 and 76 interengage the upper base component as
shown in order to form an enclosure similar to that formed by lower cage
assembly 28, for at least partially enclosing an upper housing port 16 of
the connector housing 12. In addition, sidewalls 74, 76 of upper cover
component 60 also extend toward printed circuit board 11 to substantially
enclose side portions of both upper cage assembly 30 and lower cage
assembly 28. The lower base component 32 may be provided with mounting
pin portions 48 that are stamped out of the bottom wall 40 thereof and
which are formed, or bent, so that they extend vertically with respect to
the lower base bottom wall 40, and generally in the same plane as the
sidewalls 42, 44. The mounting pin portions 48 are formed in a desired
pattern to engage and mate with corresponding mounting holes on printed
circuit board 11. Similar mounting pin portions 80 may be formed to
extend along lower edges of extended sidewalls 74, 76 of the cover member
60 to engage mounting holes in printed circuit board 11. Connector
assembly 10 also includes a separate rear wall 78 that is attachable to
the upper and lower cage assemblies 28, 30. The rear wall 78 forms an
enclosure surrounding the terminal tail portions 22, tail aligner 24 and
the rear portion of connector housing 12 when attached to cage assemblies
28, 30, and the rear wall 78 includes mounting pin portions 80 extending
from its bottom and extending vertically. The pin portions 80 engage
mounting holes on printed circuit board 11.

[0070] Referring to FIGS. 4-7, a light pipe assembly 82, is shown as part
of the overall connector assembly 10. The light pipe assembly 82a of FIG.
4 will be referenced for the purpose of describing the basic components
of the light pipe assemblies. However, it will be understood that light
pipe assembly 82b of FIG. 5 has the same basic features as light pipe
assembly 82a. Light pipe assembly 82 includes at least one light pipe 84
manufactured from a material suitable for carrying light, such as a
plastic or glass. The pipes 84 are illustrated as pairs of pipes, with
each pair shown extending alongside the shielding cage assembly of the
connector assembly. FIGS. 4 & 5 show assemblies which are formed using
multiple light pipes. The light pipes 84 may be color-coded and each
light pipe 84 has a light-receiving input face 86, a light emitting
output or display face 88, and a body portion 90 extending between the
input and output faces. Light pipes 84 are shaped to carry light signals
from input faces 86 through body portions 90 to output faces 88.

[0071] Portions of light pipes 84 may be affixed to one or more support
members 92. Support members 92 provide a framework for positioning and
securing light pipes 84 with respect to each other and with respect to
cage assemblies 28, 30. Thus, portions of support members 92 may be
formed so as to enable engagement with features on one of cage assemblies
28, 30. Support members 92 may be formed integral with light pipes 84.
When the light pipe assembly 82 is mounted to cage assemblies 28, 30,
input faces 86 of each light pipe 84 will be positioned so as to reside
opposite a respective light source such as an LED on the circuit board
11.

[0072] As shown in FIGS. 4 and 6, a light pipe assembly 82a is externally
mounted with respect to cage assemblies 28, 30. FIGS. 4 and 6 show one
possible configuration, in which two pairs of light pipes are spaced
apart vertically and connected to a pair of support members 92a. Light
pipe assembly 82a may be connected to one or more of the cage assemblies
28, 30 using any one of several known methods. Examples of possible
attachment methods include a mating-type connection between complementary
features formed in light pipe assembly 82a and cage assembly 28, 30,
mechanical fasteners, or adhesives. A portion of light pipe assembly 82a
may also be secured to printed circuit board. One or more light pipe
assemblies 82a may also be mounted along multiple sides of connector
assembly. Thus, the light pipe assembly 82a may be configured in any
desired manner to enable attachment to an existing connector assembly and
to convey light between light emitting elements and light receiving
elements having any one of a variety of spatial locations with respect to
the connector assembly.

[0073] The shapes of light pipes 84a and the dimensions and positioning of
support members 92a may be chosen to convey light between light emitting
elements and light receiving sensors having a wide variety of locations
in relation to connector assembly 10. For example, as seen in FIG. 6, the
configurations of light pipes 84a and support members 92a may be
specified such that light pipe input faces 86a will receive light from
respective LED's positioned on the circuit board 11 at various distances
from connector assembly 10. Also, the configurations of light pipes 84a
and support members 92a may be specified such that light pipe output
faces 88a will emit light to light receiving sensors located at any one
of a variety of distances from printed circuit board 11.

[0074] Referring to FIG. 5 a light pipe assembly 82b may be provided that
includes one or more pairs of individual light pipes arranged in pairs.
Each assembly 82b can be seen to include a pair of adjacent light pipes
84b that are attached to one or more support members 92b. The light pipes
84b each opposing input faces 86b, output faces 88b and body portions 90b
that extend between the input and output faces 86b, 88b. In this
embodiment, the light pipes are configured to be mounted within the upper
cage cover component 60 as shown by the alternate embodiment arranged in
FIG. 7. In this embodiment, the pipes extends within the connector
housing recess 20 and cavity 18 formed between housing upper port 16 and
housing lower port 14.

[0076] As may be seen in FIG. 5, the input faces 86b of light pipes 84b
may be arranged in a "front-rear" configuration with respect to the
mating direction of connector assembly 10 indicated by arrow "A". The
body portions 90b of the light pipes 84b include vertical portions 96b
extending upward from printed circuit board 11 and terminating in right
angle bends 98b. Horizontal portions 100b of light pipes 84b extend from
right angle bends 98b toward a front portion of the connector assembly,
terminating in a transition region, generally designated 102b. It may be
seen from FIG. 5 that horizontal portions 100b extending forward from
right angle bends 98b have an "over-and-under" orientation.

[0077] Referring to FIGS. 5 and 7, it may be desired to arrange output
faces 88b of light pipes 84b in a "side-to-side" configuration with
respect to the connector assembly mating direction. Thus, the
configuration of light pipes 84b must transition from the
"over-and-under" orientation of horizontal portions 100b to the
"side-to-side" configuration. This transition is shown best in FIG. 5.
The transition in the configuration of the light pipes between right
angle bends 98b and output ends 88b is achieved by forming, in transition
region 102b, angled portions 104b in each of the body portions of the
light pipes. The transition region 102b preferably resides within housing
cavity 18.

[0078] FIG. 5 shows one possible arrangement of angled portions 104b in
transition region 102b. At points on the light pipe body portions 90b
which are located within the housing cavity 18, the body portion 90b of
the bottommost light pipe 84b angles inward and upward, while the body
portion 90b of the top most light pipe 84b angles outward and downward.
The straight sections 106b of the body portions 90b then proceed from
angled portions 104b toward a front portion of connector assembly 10
proximate the connector receiving openings in cage assemblies 104b. As
seen in FIG. 5, the body portions 90b may be angled such that straight
sections 106b are spaced apart from each other and spaced approximately
the same distance from printed circuit board 11.

[0079] A support member 92b may be positioned between body straight
sections 106b proximate angled 104b to position and secure the light pipe
straight sections 106b with respect to each other and with respect to
connector housing 12. The width of support member 106b may be set to
provide and maintain a desired predetermined spacing between straight
sections 106b. Also, the length of support member 92b may be set to
provide a press fit between upper cage base component 58 and lower cage
cover component 34 when light pipe assembly 82b is inserted into the
cavity 18 formed between the upper port 16 and lower port 14 of the
connector housing. The support member 92b may also be plated with a
metallic material to form a conductive member extending between upper
cage assembly base component 58 and lower cage assembly cover component
34. This provides additional grounding contact between cage assemblies 28
and 30.

[0080] FIGS. 7 and 8 show that portions of light pipe straight sections
106b that include output faces 88b may be received in a shroud, or endcap
108. The end cap 108 may be preferably formed using conductive materials
to provide some degree of EM shielding. The endcap 108 secures the light
pipe output faces 88b in a pattern, and provides additional EMI shielding
for the overall connector assembly. For these purposes, the end cap 108
may be disposed to create intimate contact with both the upper cage
assembly 58 and the lower cage assembly 36 and may be connected to a
grounding member on the printed circuit board 11.

[0081] In FIGS. 7 and 8, two light pipe assemblies 82b are embodied in two
pairs of spaced apart light pipes 84b extending along opposite sides of
connector housing 12. In this embodiment, the light pipe assemblies 82b
reside within housing recesses 20, within upper cage cover component 60,
and within the cavity 18 formed between upper port 16 and lower port 14.
As such, the light pipe assembly 82b resides within the existing printed
circuit board "footprint" of the connector assembly as defined by
connector housing 12 and the cage assemblies that enclose the housing.
Thus, this embodiment of the connector assembly incorporates a light pipe
assembly therein without occupying additional space on printed circuit
board 11.

[0082] Assembly of the connector assembly 10 of FIGS. 1, 2 and 6 will now
be described. In a first step, the terminals may be press-fit into
connector housing 12. Terminal tail portions 22 are then inserted into
tail aligner holes 26 and the tail aligner 24 is secured to connector
housing 12, thereby securing tail portions 22 with respect to housing 12.
The upper and lower cage assemblies 58, 36 are then secured over the
connector housing 20 to upper and lower housing ports 14 and 16,
respectively.

[0083] The rear wall 78 of the cage assembly is then attached to the
shielding cage assembly over the upper and lower assemblies 30, 28 and
the upper cover component 60 to enclose terminal tail portions 22, tail
aligner 24 and to close off the rear portion of connector housing 12. The
rear wall 78 is generally secured in intimate contact with one or more
walls of each of upper cage assembly base component 58, upper cage
assembly cover component 60, lower cage assembly base component 32 and
lower cage assembly cover component 34. As stated previously, mounting
pin portions 80 may also be formed on the shielding cage rear wall 78 in
a desired pattern to engage and mate with corresponding mounting holes on
the circuit board 11. These holes may be plated through holes which are
electrically coupled to circuit traces on printed circuit board 11. These
circuit traces are connected to one or more grounding features, thereby
providing a grounding path for electromagnetic energy flowing through
cage assemblies 28 and 30. After securing rear wall 78 to upper and lower
cage assemblies 28 and 30, the connector assembly 10 may be electrically
attached as a single unit to the printed circuit board 11.

[0084] Assembly of the second embodiment of connector assembly 12 will now
be described with reference to FIGS. 1, 2, 7 and 8. In a first step, the
terminals are press-fit into connector housing 12. Terminal tail portions
22 are then inserted into tail aligner holes 26 and tail aligner 24 is
secured to connector housing 12, thereby securing tail portions 22 with
respect to housing 12. In this embodiment, the lower cage assembly 28 is
then secured to the connector lower housing port 14, and the base portion
58 of the upper cage assembly 30 is then attached to the connector upper
housing port 16. The light pipe assembly 82b is then press-fit into
housing recess 20 and the housing cavity 18. Upper cage assembly cover
component 60 is then attached to upper cage assembly base component 60,
thereby enclosing light pipe assembly 82b within side walls of upper
cover component 60. The spacing between the upper and lower cage
assemblies 30, 28 defines a cavity that extends lengthwise of the
connector assembly and this cavity accommodates the horizontal extent of
the light pipe assemblies.

[0085] The rear wall 78 may then attached to cage assemblies 28, 30 to
enclose terminal tail portions, tail aligner 24 and the rear portion of
connector housing 12 as described above. After securing rear wall 78 to
upper and lower cage assemblies 30 and 28, connector assembly 10 may be
electrically attached to printed circuit board 11. FIG. 9 illustrates a
different connector 201 that supports a plurality of conductive terminals
203, each terminal of which may be stitched into rear openings 204
disposed in an insulative housing 205 of the connector 201. The connector
201 is shown in its eventual mounting location on the circuit board 202
and the connector housing 205 illustrates in this embodiment includes a
pair of card edge connector portions 206 which are disposed in a
"stacked", or vertically spaced-apart, fashion along the front face 207
of the connector housing 205. The stacked connectors 201 are enclosed
within a metal shielding cage assembly 220 that has two module-receiving
bays 221 defined therein. Each of these bays 221 is intended to receive
an electronic module 222 therein in a fashion that is well known in the
art. The module-receiving bays 221 are also stacked or spaced-apart
vertically from each other and, due to the cage construction, an
intervening space 223 that extends lengthwise through the shielding
assembly 220 is defined between the two bays 221.

[0086] The light pipe assembly 200 includes two pairs 210 of light pipes
212 that extend forwardly of the connector 201 along the sides of the
connector housing 205 and into the intervening space 223 between the two
bays. The light pipes 212 are generally L-shaped and have first ends 214
(FIG. 10) that are positioned in opposition to illuminators 225 located
on the circuit board 202. The second ends 215 of the light pipes are
located on the opposite ends of the light pipes 212 and as illustrated,
are preferably held in place and in a selected alignment by an end cap
216, which typically would be formed of a conductive material. This is so
that the endcap 216 may provide a means of electrically connecting the
two module-receiving bays of the shielding assembly together as well as
providing a measure of electromagnetic interference shielding across the
intervening space in which it resides. The exterior shielding cage
assembly includes a rear wall 250 that may be formed as a separate piece
or may be formed as part of the top cage assembly. In the former
instance, the rear wall 250 is separately attached to the cage assembly
and in the latter instance, it is preferably folded down over the back
opening of the cage assembly and then attached to the upper cover 251.
Instances where the rear wall 250 is formed as part of the upper cover
251, it is attached thereto along and end 252 and then folded back over
the rear opening. In either instance, the rear wall 250 is preferably
secured by integrated clips 254 or pins or the like.

[0087] The end cap 216 is received within (as are the horizontal portions
of the light pipes 215) the intervening space 223 that separates the two
bays 221. The end cap 216 may include indicia 217 that identify the
function of the connector 200, i.e., whether the modules are connected to
the connector or whether the modules are energized or the like. As shown
best in FIG. 11, the end cap 216 may include a plurality of engagement
members, shown as raised members 218 that engage opposing elements formed
on the top bay 221 of the shielding assembly 220. Slots 219 may be formed
in the members 218 to receive members 225 formed in the top bay 221 (FIG.
9). Similarly, the square, raised member 218 may be received in a
like-sized opening 226 that is disposed in the upper cage assembly 220.
Each pair 210 of light pipes may further include a support bar 230, shown
vertically, that may be integrally formed with the pair 210 of pipes in
order to space the pipes of each pair 210 apart a selected distance. In
order to engage the connector and to partially support the pipes in their
extent, the pairs of light pipes may further each preferably include
engagement members 232, shown as hook-type lugs that extend inwardly of
the pipe pairs 210. As shown best in FIG. 16, these lugs 232 are received
within cavities, or slots 209 that are formed in the front face of the
connector housing 205. As shown in the Figures, the lugs 232 are
L-shaped, but any configuration that holds the pipes in place will
suffice.

[0088] As shown best in FIG. 13, the light pipes may have thick body
portions 235 that reduce down in thickness to thin second end portions
236. These end portions 236 are received within complimentary openings
237 formed in the end caps 216 and which extend lengthwise through the
end cap 216. In this regard, the end cap 216 may keep the pipes together
in a selected alignment along their lengthwise extent through the
intervening space 223 between the two module-receiving bays 221 of the
shielding assembly 220. As shown best in FIGS. 17A & 17B, the connector
housing 205 has recesses 208 formed along the sidewalls of the connector
housing 205, and the recesses are shown as positioned generally on the
connector housing 205 at a level midway of the height of the connector
housing 205, but the recesses may be located elsewhere.

[0089] FIG. 18 illustrates another connector assembly that incorporates
light pipes constructed in accordance with the principles of the present
invention. In FIG. 18, only the shield assembly 301 is illustrated along
with the circuit board 302 and the light pipe end cap 304. In assembly,
the shield assembly 301 receives the connector housing 205 from the rear
opening and then the rear wall member 314 is applied to the shield
assembly 301 so as to form an integrated assembly that is applied to the
circuit board 302 as a single element, rather than applied over a
discrete connector applied to the circuit board. The shield assembly 301
is configured to define a pair of module-receiving bays 305 that are
spaced apart from each other in the vertical direction so as to be
considered stacked upon each other. The bays 305 are separated by an
intervening space 306 that is shown occupied by the end cap 304 and
through which the light pipes extend. The shielding assembly 301 is shown
as including a hollow enclosure 310 that has a bottom wall 311,
intervening walls 312, 313 and a rear wall 314 that closes off the
enclosure after the connector and light pipe assemblies have been
inserted as a unit from the rear of the shielding assembly 301. The
intervening walls 312, 313 have tabs 315 that extend into and preferably
through openings 317 that are formed in the side walls of the enclosure
310.

[0090] In FIG. 19, the shielding assembly 301 is removed from the circuit
board 302 for clarity in order to expose the internal connector 320 and
the light pipe assembly 330 to view. The connector component 320 includes
an insulative housing 321 with two edge card-receiving slots 322 spaced
vertically apart from each other so that each slot 322 is aligned with
one of the two module-receiving bays 305. The connector housing 321
includes a plurality of cavities, each of which receives a single
conductive terminal 324 therein. As is known in the art, each terminal
may include a contact portion that is exposed within the card slots 322.
A light pipe assembly 330 is shown with two pairs of light pipes 331
which are separated from each other horizontally. These pipes have
indicator ends 332 received within an end cap 304, which includes
openings 333 which communicate to the pipe indicator ends 332.

[0091] As shown best in FIG. 21, the light pipe assembly 330 preferably
includes two distinct elements, which may be referred to as first and
second arrays 336a, 336b of light pipes. Each such array 336a, 336b
includes two light pipes 331 that are spaced apart from each other. The
spacing between the two pipes is closer in the first array 336a than it
is the second array 336b. (FIG. 22.) In this manner the light pipes 331
of the first array 336a may be received within the space between the two
pipes 331 of the second light pipe array 336b. In such a fashion, the
first array 336a may be considered as at least partially "nested" within
the second array 336a.

[0092] Similar to the other embodiments, the two light pipes 331 of each
array 336a, 336b are held together in their spacing by a support or tie
bar 337a, 337b which extends horizontally somewhat above the light pipes
331 of the first array 336a and somewhat underneath the light pipes 331
of the second array 336b. The light pipes are generally L-shaped and have
opposing ends 338, 339, with one end 338 being positioned over or on an
illuminator device 345 disposed in the circuit board 302 near the sides
of the connector 320. With the support bars 337a, 337b of the light pipe
arrays 336a, 336b being inverted, it is possible to place the first array
336a of pipes on and within the second array 336b of pipes. The support
bars 337b of the second light pipe array 336b in effect, define a "nest"
into which the horizontal extent of the first light pipe array 336a are
received. This nesting is shown best in FIGS. 23A, 26A & 26B.

[0093] The rearmost support bars 337a, 337b of each of the light pipe
arrays 336a, b include means for engaging the connector 320 and such
means are illustrated as pairs of engagement hooks 339 that extend
rearwardly from their support bars 337a, 337b. These hooks 339A are
received within recesses 340 that are formed in the connector housing 321
and which, as shown best in FIG. 23B, include shoulder portions 341 which
the engagement hooks 339A engage. The engagement hooks 339A of the first
array 336a are received in the top row of recesses 340 as shown in the
sectional view of FIG. 23B, and the engagement hooks 339 of the second
array 336b are received within the bottom row of recesses 340 (FIG. 20).

[0094] The offset nature of the support bars 337, 338a, 338b also
facilitates the fitting of the light pipes into the intervening space 306
between the top and bottom bays 305 by reducing the overall height of the
horizontal extent of the light pipe arrays 336a, 336b. The end cap 304
may include slots 344 that are formed on the top and bottom surfaces
thereof receive stubs 346 formed on the intervening walls of the
shielding assembly 301.

[0095] FIGS. 27 and 28 illustrate an embodiment 400 in which the light
pipe assembly 401 is integrally formed as a single piece, such as by
injection molding or any suitable process. In FIG. 28 the light pipe
assembly 401 has two pairs of light pipes 403 associated which are
interconnected together by support members 405 to form a lattice-like
structure. The support members 405 are shown interconnecting together
both the vertical and horizontal portions of the light pipes. Another set
of support members 407 may interconnect the horizontal portions and may
include engagement members 409 formed therewith, which are received
within corresponding openings 412 disposed in the front face 413 of the
associated connector component 420. The forwardmost support member 405
may also include an engagement member, shown as a hook member 423 that
engages the shoulder 430 of an end cap 431. Once again in this
embodiment, the light pipe assembly 401 is supported entirely along the
front face 413 of the connector 420 and not by any side portions thereof,
which assists in reducing the overall width of the connector assembly and
exterior shielding assembly (not shown).

[0096] FIG. 29 illustrates a connector 500 suitable for use in small form
factor applications and particularly with the aforementioned light pipe
assemblies, and which is constructed in accordance with the principles of
the present invention. The connector 500 includes a housing 502 that is
preferably formed from an insulative material, which may be injection
molded or the like. The housing 502 has a forward engagement portion 504
with a frontal face 506. The forward engagement portion extends forwardly
into the interior space of the exterior shielding assembly. The housing
illustrated includes a base portion 508 and a top portion 510. The base
and top portions 508, 510 extend rearwardly from the forward engagement
portion 504 and cooperatively define what may be considered as an
internal cavity 511 of the connector that opens to the rear of the
connector (FIG. 31). The base portion 508 is intended for mounting to a
circuit board (not shown) and therefore may preferably include mounting
members, like posts 509 and stabilizing lugs 507 extending out from the
connector housing sides laterally so the bottom surfaces thereof may abut
the circuit board.

[0097] The housing internal cavity 511 houses a plurality of terminal
assemblies 520, one of which is illustrated best in FIG. 33. As shown in
FIG. 33, the terminal assembly 520 includes a plurality of conductive
terminals, shown as two pairs of terminals. The terminals 521 of each
pair are spaced apart from each other vertically, and the two pairs
themselves are likewise spaced apart from each other in the vertical
direction. This spacing permits the terminal assemblies 520 to be used in
connector 500 of the present invention which are suited for stacked or
dual configuration. The terminals 521 are initially supported in a lead
frame and inserted into a mold where the terminals 521 are separated and
a supporting dielectric frame 522 is molded over portions of the
terminals 521, such as by over molding. The dielectric frame 522 provides
a measure of thickness to the terminal assembly 520 and defines a body
portion of the assembly. The terminals are trimmed into separate
terminals by a process known in the art. The terminals are preferably
arranged in an inverted-L configuration as shown so as to maintain the
depth of the connector at an optimum amount and so as to accommodate the
clips 535.

[0098] The terminal assembly 520 preferably has a generally square or
rectangular configuration, as shown, with four distinct sides. The
terminals 521, as shown best in FIG. 34, include contact portions 523
that extend along one side 524 of the assembly 520 and tail portions,
shown as compliant pin portions 525, that extend along and out from
another side 526 of the terminal assembly 520. These two sides 524, 525
are adjacent each other as shown, although other configurations are
suitable. The terminals 521 further include body portions 527 that
interconnect the contact portions 523 and the tail portions 525 together
and the overall configuration of the terminals 521 of the assembly 520
may be considered is L-shaped. The dielectric frame 522 may include, as
best shown in FIG. 33, openings 528 that follow the path of the terminals
521, with one opening tracking one terminal. These openings 528 expose
portions of the terminals 521 to air and are suitable for providing an
air-terminal interface between selected portions of terminals of the
connector. This exposure to air may be used for affecting the impedance
of the system in which the connector 500 is used, and particularly the
impedance of the terminals 521 of the terminal assemblies 520. The rear
edge, or side 5280 of the terminal assemblies 520 may include notches
530, or other suitable openings which may receive a transverse alignment
bar (not shown) for maintaining the rear sides 5280 of the terminal
assemblies 520 together in alignment as a single group.

[0099] In one important aspect of the invention, and as best illustrated
in FIGS. 33 and 34, each terminal assembly 520 is preferably provided
with means for engaging the connector housing 502, and this engagement
means is illustrated in the drawings as an elongated clip member 535 that
is disposed along one side, namely, the front side 524 of the terminal
assembly 520. This clip member 535 is disposed between the two sets of
terminal contact portions 523 and it also extends forwardly of the
terminal assembly frame 522 in order to contact an opposing ledge 537 or
similar engagement member that is disposed in the connector housing 502.
This engagement member is shown best in FIG. 35 in the form of a
shoulder, or bar, 537 that extends horizontally as shown and which
projects rearwardly in the internal cavity 511 of the connector housing
502. As shown best in FIG. 32, the shoulder is preferably provided with a
plurality of slots 539 (FIG. 31) that are spaced apart from each other
widthwise of the connector housing 502, and which extend lengthwise
within the connector housing 502 toward the front of the connector 500.
Each clip member 535 preferably includes a pair of free ends 540 that are
spaced apart (shown in the vertical direction) to define a small bight
therebetween, which preferably is less that the thickness of the bar 537
so the clips 535 may engage the bar 537 reliably and exert a positive
retention force thereon.

[0100] The terminal contact portions 523 likewise may be received within
corresponding terminal-receiving slots 542 that are formed in the
connector housing 502 and which are typically disposed on opposite sides
(top and bottom) of the card-receiving slots 505 (FIG. 36). The terminal
assembly engagement clip members 535 are preferably formed from a durable
metal that is strong enough to maintain a reliable grip on the opposing
shoulder 537 of the connector 500. The clip member 535 may be easily
molded as an insert into the dielectric frame 522 of the terminal
assembly 520, and as illustrated in FIG. 34, may include a wide body
portion 545 with an opening 546 formed therein to improve the retention
of the clip 535 in the frame 522. The clip members 535 provide a third
point of engagement with the connector housing 502, with the first two
points of retention being the two sets of the terminal contact portions
523 which are retained within their corresponding terminal-receiving
slots 542.

[0101] Turning now to FIG. 36, the connector 500 is seen in frontal
elevation, which best illustrates the number of engagement portions that
are disposed on the connector housing 502 and arranged on the front face
506 thereof. As described above, the connector housing 502 may include
openings 340 formed therein that receive the engagement hooks 339 of the
light pipe arrays 336a, 336b. These openings 340 are preferably disposed
on the connector front face 506 in the area between the two card
edge-receiving slots 505 of the connector 500, and further preferably are
disposed in between the shielding assembly engagement openings 550.

[0102] An additional set of openings 550 (FIG. 38) are disposed on the
front face 506 and these openings extend horizontally within the
connector housing 502. These openings receive engagement members, in the
form of tabs or lugs 552 of the portion of the exterior shielding
assembly that defines an intervening wall between the two
module-receiving bays of the shielding assembly. This is shown best in
FIGS. 35 and 40. These slots 550 extend rearwardly in the housing 502 and
include an inner ledge 551. This inner ledge 551 provides a shoulder for
a tang 553 on the shielding assembly engagement tabs 552 to bear against
and retain the shield in place and in alignment with the connector
housing 502. Both these openings 550 and the light pipe engagement
openings 340. In this manner, the light pipes and the shielding assembly
all engage the connector housing 502 in a secure manner so that all of
the components will act as a single assembly. In this manner, the light
pipes and connector may be assembled as a unit and inserted into the
shielding assembly from its rear.

[0103] The base portion 508 of the connector housing 502 has an opening
that communicates with the internal cavity 511 of the housing 502. This
permits the bottom edges 526 of the terminal assemblies 520 to lie flat
on the surface of the circuit board, if desired and as shown best in FIG.
35.

[0104] While the preferred embodiment of the invention have been shown and
described, it will be apparent to those skilled in the art that changes
and modifications may be made therein without departing from the spirit
of the invention, the scope of which is defined by the appended claims.